Intermittent process for manufacture of a multiple filter rod having spaced pockets containing particulate material

ABSTRACT

A filter rod making machine is modified to include a dispensing device for granular or particulate material which is fed through spaced apertures to a substantially U-shaped web of selected filter material. The linear movement of the filter material is momentarily stopped to facilitate the reception of the granules. Towards this end, metered amounts of the gravity fed granules are delivered to the spaced apertures by a reciprocal dispensing plate actuated during the dwell period that the web is stationary. Thereafter the U-shaped filter material with spaced charges of granules are shifted longitudinally away from the granule application station in order that a corresponding length of the filter rod may receive spaced charges of the granules. This intermittent motion of the web through the granule application station is repeated. While the tow is moved with intermittent motion through the application station, it is continuously fed from a tow opening unit through a plasticizer applicator and over a feed drum.

United States Patent 91 Sexstone [451 Sept. 24, 1974 [75] Inventor: John H. Sexstone, Middletown, Ky.

[73] Assignee: Brown & Williamson Tobacco Corporation, Louisville, Ky.

OTHER PUBLICATIONS Defensive Publication 775576 (T860013), Mar. 25, 1969, Hawkins et al.

Primary ExaminerRoy Lake Assistant ExaminerJames F Coan Attorney, Agent, or Firm-Vance A. Smith [5 7] ABSTRACT A filter rod making machine is modified to include a dispensing device for granular or particulate material which is fed through spaced apertures to a substantially U-shaped web of selected filter material. The linear movement of the filter material is momentarily stopped to facilitate the reception of the granules. Towards this end, metered amounts of the gravity fed granules are delivered to the spaced apertures by a reciprocal dispensing plate actuated during the dwell period that the web is stationary. Thereafter the U- shaped filter material with spaced charges of granules are shifted longitudinally away from the granule application station in order that a corresponding length of the filter rod may receive spaced charges of the granules. This intermittent motion of the web through the granule application station is repeated. While the tow is moved with intermittent motion through the application station, it is continuously fed from a tow opening unit through a plasticizer applicator and over a feed drum.

20 Claims, 7 Drawing Figures INTERMITTENT PROCESS FOR MANUFACTURE OF A MULTIPLE FILTER ROD HAVING SPACED POCKETS CONTAINING PARTICULATE MATERIAL BACKGROUND OF THE INVENTION In an effort to improve the absorbent properties of tobacco smoke filters, various additives in the form of particulate or granule material have been incorporated. Towards this end, finely divided charcoal, silica gel, volcanic salts, ion exchange resins, clays and the like as well as other absorbents and adsorbents have been introduced. This introduction has been by dusting, spraying, slurrying, or otherwise incorporating the additives into the material which forms the major part of the filter structure. The fibrous material may be paper, bulked yarn, filamentary tow or any other material known to the art. When the granular additives are introduced to the fibers or interspersed therein, there is a tendency for them to sift out or migrate during the filter forming operation or while the filter element is in use. In addition, the sifting out of the particulate material would prove distasteful particularly when the migration resulted in granules finding their way into the mouth of the smoker. In this connection, attempts to introduce adhesives to fix the location of the additives has not proved successful because such adhesives would generally deactivate the adsorbent properties of the additives.

Another method of manufacturing multiple filters with granule or particulate additive material involved the handling of short filter segments of selected material and arranging them in spaced relationship and thereafter incorporating the additives between segments to provide a multiple filter rod having a loose granule section. The filter rod is eventually cut to provide multiple filters having an intermediate granule section. This technique, although effectual, does involve expense which is increased significantly with cost of the particulate material introduced. Furthermore, the handling of short filter plug lengths and introduction of the particulate material in the contemplated manner, particularly on high speed machinery incurs many difficulties including wastage and down-time of the production machinery.

As a rule, a tremendous house-cleaning problem ensues with most of the heretofore employed or contemplated techniques and methods. As a result rather large and expensive equipment has been incorporated which also adds to the overall cost of the finished filter rods.

Several processes and apparatus have been proposed for obviating the disadvantages of the prior art. For example, U.S. Pat. No. 3,371,000 and Defensive Publication No. 775,576 disclose techniques for introducing the granular additive material at spaced intervals in continuously moving filter material. Eventually a filter rod is formed having spaced sections containing granular material.

Based on the teachings of U.S. Pat. No. 3,371,000 problems still exist with migration of the granular material. This patent is directed to a process in which it is difficult to control the dispensing of granules as well as their location within the formed cigarette rod so that the rod may be cut between the granular zones thereby preventing granules from being exposed to the lips of the smoker.

Another difficulty with the introduction of particulate material in continuously moving tow is the contamination of the cutting areas and consequently tobacco as a result of the migration. Furthermore, this situation is aggravated because of triangulation of the spaced particulate pattern whereby the pattern is not evenly or concentrically arranged with respect to the rod axis. This is caused by the serging pressure on the side of the tow by the rod forming machine which results in spiraling of the spaced pattern in the finished rod.

Based on direct and actual knowledge, neither of these patented approaches have resulted in a commercial application; and it is towards this end, that the present invention is dedicated.

SUMMARY OF THE INVENTION The present invention relates to an intermittent process for the manufacture of a continuous filter rod having at spaced intervals pockets containing a selected additive in particulate or granule form with registry of the pockets being assured and migration of granules eliminated.

Another object is to provide an intermittent process for the manufacture of multiple filters having an intermediate pocket of a granular additive of reduced pressured drop for assuring the directing of the tobacco smoke to this zone in order that the smoke may be treated as desired.

A further object is to provide for the intermittent process for the manufacture of a multiple filter rod of this type in an efficient manner and on a commercial scale without any of the disadvantages of the aforenoted prior art techniques.

Still another object is to provide an intermittent process for the manufacture of a multiple filter rod of the foregoing type in which a selected additive is introduced into linearly extending filter material in a controlled and accurate manner.

Other objects and advantages will become apparent from the following detailed description which is to be taken in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS In the drawings:

FIG. 1 is an elevational view of a filter rod forming machine incorporating an intermittent granular application station according to the teachings of this invention;

FIG. 2 is a length of filter rod formed by the machine of FIG. 1 with certain parts broken away and removed showing pockets at spaced intervals in the tow, containing a selected additive in particulate or granule form;

FIG. 3 is a cross-sectional view taken along the line 3-3 of FIG. 2;

FIG. 4 is an enlarged fragmentary sectional view showing the granular appplication station including a hopper, spaced longitudinally arranged apertures through which the granules are gravity fed onto the filter material of the U-shaped configuration and a reciprocal dispensing plate which places metered amounts of granules from the hopper into the apertures with associated componentry at the inlet and outlet of this station;

FIG. 5 is a fragmentary cross-section view taken along the line 55 of FIG. 4 showing the formation of the filter material into the U-shaped configuration;

FIG. 6 is a fragmentary sectional view taken along the line 66 of FIG. 4 showing the association of the dispensing plate with the outlet end of the hopper and the inlet end of the discharge apertures through which metered amounts of the granules are deposited within the U-shaped filter material; and

FIG. 7 is a fragmentary sectional view taken along the line 7 -7 of FIG. 4 showing the filter material about to be formed over the granules to form a continuous rod having spaced pockets containing this material.

DETAILED DESCRIPTION Referring initially to FIG. 1, apparatus 10 is provided for forming a multiple filter rod having spaced pockets containing a finely divided additive in particulate or granular form. Lengths of this continuous rod are cut by apparatus 10 and suitably removed at the discharge end thereof. An exemplary rod length 12 formed by such apparatus is illustrated in FIG. 2. In forming this length 12 of multiple filter rods a filter material such as fibrous cellulose acetate tow 14 may be utilized. In lieu of cellulose acetate the filter material may be paper, bulked yarn or other filamentary tow or any other suitable material. The spaced pockets 16 may contain an additive 18 having the desired absorbative or adsorbative properties either in particulate or granular form. The granules 18 may be finely divided charcoal, silica gel, volcanic salts, ion exchange resins, clays and the like. A particular additive contemplated by this invention is the ion exchange resin Duolite which may be of the type disclosed in commonly assigned US. Pat. No. 3,716,500 granted Feb. 13, I973.

The continuous cellulose acetate tow is drawn from the usual storage bail into tow opening unit 20 which spreads or blooms the tow in a manner well known to the art of filter manufacture. The opened or spread tow 22 passes through a conventional plasticizer applicator 24. The plasticizer for cellulose acetate tow that is usually employed is triacetin. The tow with plasticizer is transferred to the nip of delivery roll 26 and roll 28. As will be explained in detail shortly, the tow is intermittently fed through the application station 34; and accordingly a dancer roll arrangement 30 accommodates the continuously delivered tow during the dwell or the period the tow is stopped in the application station 34. This accommodation is depicted in phantom in FIG. 1. The trumpet 32 located at the inlet end of the granular application station 34 is designed to place the flattened tow 22 into an essentially U-shaped configuration, as shown in FIG. 5, preparatory to receipt of the spaced charges of granular material 18.

The applicator station as shown in detail in FIGS. 4 and 6 and operates to deposit metered amounts of the selected granular material at spaced intervals within the base of the U-shaped web 22 leading from the trumpet 32. The granular material 18 is gravity fed from the hopper 42 filling the cavities or openings 43 of reciprocal dispensing plate 44. Openings 43 are adapted to be aligned or registered with discharge openings 45 through which metered amounts of the granules delivered by dispensing plate 44 are adapted to be deposited on the momentarily stopped web 22 of tow. Apertures 45 are longitudinally arranged to place the granule charges at predetermined space intervals along the web 22. The intermittent motion of the web 22 is imparted by the intermittently driven suction belt 46 which delivers the predetermined length of web 22 with spaced granule charges 18 thereon from the applicator station 34 to place the next such length of web 22 at this station. In order to facilitate and expedite the deposit of the charges 18 on the web 22 from the discharge openings 45 at the same time prevent granule migration, a vacuum system 47 draws a vacuum and consequently creates a suction through the belt 46 and web 22 during the granular dispensing operation. As will be appreciated this vacuum may be continuously applied or intermittently applied during dispensing. As will be apparent the dispensing plate 44 will initially be disposed as shown in FIG. 6 with its opening 43 disposed under the outlet end of the hopper 42 for reception of the metered amounts of granular material. When the web 22 has stopped at the applicator station 34 the plate 44 will be shifted to align these openings 43 with the apertures 45 causing the metered amounts of granule material to fall onto the stationary web with the aid of the applied suction of vacuum system 47. Thereafter the plate 44 will be shifted to its starting position for the next granule dispensing operation.

The U-shaped tow 22 with the spaced charges of selected granular material 18 pass into a rod former and guide 50 immediately after the wheel applicator station 34. The unit operates to initiate the gathering of the legs of the U-shaped tow 22 about the spaced granular material 18. The essentially cylindrical tow with spaced pockets of granular material 18 together with the wrapper 36 is intermittently driven by belt 40 is fed into a garniture 52 to complete the formation of the rod. The garniture tongue exposes one of the marginal side edges of the wrapper 36 to the glue application 54 and this edge is folded on the other edge by folder 55 with the applied glue in between for purposes of sealing the wrapper about the tow. The wrapper tow is fed through heater 56 and subsequently into the cut-off station 58 at which the wrapped rod is cut into lengths 12 (See FIG. 2). The operation of the feeder is synchronized with the feed of the tow through the applicator station 34 and the feed of the wrapper 30. Thus, the operation of the cut-off device may be intermittent.

When the individual plugs of rod length 12 are cut as indicated in FIG. 2 and applied to the butt end of a cig-,

arette the smoke of the lit cigarette when puffed by the smoker, is assured exposure to the pocket 16 and consequently the granular material therein as a result of this zone of reduced pressure drop. In this manner the smoke will be conditioned to the desired extent by the selected granular material 18.

The broken lines 14 indicate where cuts may be made by the cutter 58 of the plug maker 10 in order to provide quadruple length dual filter rods of the type shown in FIG. 2. There quadruple length rods are supplied to a filter tip attachment machine which cuts each quadruple length rod in half to form two dual length dual filter rods which are each assembled in axial alignment and in endwise abutting relationship with two tobacco rods with a wrapper. A final cut is made along the center line of the dual length cut rod to form two dual filter cigarettes.

Of course, separate and different additives may be mixed and placed in the individual pockets 16. For that matter, more than one pocket 16 with the same or different additives 18 may be located in each individual filter segment for incorporation on the butt end of a cigarette to attain the desired smoke treatment.

It will be apparent to those skilled in the art, that any type of additive may be introduced by the intermittent process contemplated by this invention. Furthermore, the additive introduced need not be in dry form but may be a liquid or in a slurry. In the latter form, metering types of valved dispensers or pumps may be utilized.

Thus the several aforenoted objects and advantages are most effectively attained. Although a single somewhat preferred embodiment of the invention has been disclosed and described in detail herein it should be understood that this invention, is in no sense limited thereby and its scope is to be determined by that of the appended claims.

1 claim:

1. A method of manufacturing a tobacco smoke filter comprising the steps of:

a. providing a web of selected filter material, said web having an elongated axis and being continuous in the direction of the axis;

b. continuously feeding the web in the direction of the axis;

c. stopping the travel of a predetermined length of the web for a predetermined time interval;

(1. introducing a selected additive to the predetermined length of the web during the predetermined time period; and

e. resuming the travel of the predetermined length of the web for a predetermined period and then stopping its travel again for additive introduction.

2. The method of claim 1, wherein the continuously fed web is flattened and thereafter formed into a substantially U-shaped configuration prior to introduction of the additive.

3. The method of claim 1, wherein the additive is introduced at spaced intervals in the direction of the axis of the web.

4. The method of claim 1, wherein after the introduction of the additive the web is gathered into a rod of substantially cylindrical configuration.

5. The method of claim 4, wherein a wrapper is fed intermittently in synchronization with the movement of the web axis as applied about the cylindrical rod.

6. The method of claim 5, wherein the wrapped rod is transversely cut in synchronization with movement of the web and wrapper into lengths each having at least one intermediate zone with the selected additive.

7. A method of manufacturing multiple tobacco smoke filters comprising the steps of:

a. providing a web of filter material, said web having an elongated axis and being continuous in the direction of said axis;

b. continuously feeding the web in the direction of said axis;

c. flattening said web into a predetermined width;

d. forming the flattened web into a substantially U- shaped configuration;

e. stopping the travel of the U-shaped web for a predetermined time interval;

f. providing a supply of particulate material;

g. receiving a metered amount of the particulate material from its source of supply and at spaced intervals;

h. delivering the spaced metered amounts of particulate material to the web immediately after it is formed in its U-shaped configuration;

. depositing the spaced metered amounts of the delivered particulate material into the interior of the web while stationary and at the base of the U and between the legs of the U whereby metered amounts of the particulate material will be located on the web at predetermined spaced intervals;

j. resuming the travel of the U-shaped web having the spaced metered amounts of particulate material thereon; and

k. immediately closing the legs of the web about the spaced metered amount of particulate material substantially immediately after the particulate material is deposited and forming it into a cylindrical rod.

8. The invention in accordance with claim 7, wherein a wrapper is applied about the cylindrical rod.

9. The invention in accordance with claim 8, wherein the wrapper rod is transversely cut into lengths each having at least one intermediate portion containing a pocket with the particulate material within the web of selective filter material.

10. The invention in accordance with claim 9 wherein the feed of the tow with spaced particulate material is synchronized with the feed of the wrapper and the cutting of the rod.

11. The invention in accordance with claim 7 wherein the supply of particulate material is a hopper, gravity feeding the particulate material from hopper, delivering metered amounts of the particulate material from the hopper to spaced dispensing apertures at a location above the web when the tow is stationary to enable the metered amounts of particulate material to be dispensed onto the stationary web at the predetermined spaced intervals.

12. The invention in accordance with claim 11 I wherein suction is applied to the stationary tow as the metered amounts of particulate material are dispensed thereon to expedite the dispensing operation and restrict movement of the particulate material on the web.

13. Apparatus for manufacturing multiple tobacco smoke filters comprising:

a. filter material supply means for supplying a web of filter material, said web having an elongated axis and being continuous in the direction of the axis;

b. feed means for continuously feeding the web in the direction of the axis;

c. dwell means for stopping the travel of a predetermined length of the web for a predetermined period of time;

d. additive introduction means for introducing a selected additive over the predetermined length of web in the web during the predetermined period of time; and

e. means for resuming the travel of the predetermined length of web after the additive was introduced to expose the next succeeding such length of web to the additive introduction means.

14. The invention in accordance with claim 13, wherein a dancer roll means is interposed between the feed means and additive introduction means to accommodate the web being continuously fed during the dwell periods.

15. The invention in accordance with claim 14, wherein a trumpet means is interposed between the dancer roll means and the additive introduction means to form the web into substantially U-shaped configuration.

16. The invention in accordance with claim 13, wherein the additive introduction means includes a hopper means for supplying a particulate material to spaced dispensing apertures arranged along axis of web, a reciprocal dispensing plate with cavities for holding metered amounts of the particulate material, the plate reciprocating from a first position placing cavities under hopper means to receive the particulate material and a second position during the dwell period with the cavities over and aligned with the apertures whereupon the metered amounts of particulate material are deposited on the web at spaced intervals.

17. The invention in accordance with claim l6,

wherein suction means beneath the apertures and web expedite the deposit of particulate material from the aperture onto the web.

18. The invention in accordance with claim 13, wherein garniture means immediately adjacent the additive introduction means gathers the web and forms it into a rod 19. The invention in accordance with claim 18, wherein a wrapper is fed intermittently and in synchronization with the web and the garniture means cooperates in enclosing the rod in a wrapper.

20. The invention in accordance with claim 19, wherein a cutting means synchronized with the movement of the web the movement of the web and wrapper cuts the wrapped rod into lengths each having at least an intermediate zone of the additive. 

1. A method of manufacturing a tobacco smoke filter comprising the steps of: a. providing a web of selected filter material, said web having an elongated axis And being continuous in the direction of the axis; b. continuously feeding the web in the direction of the axis; c. stopping the travel of a predetermined length of the web for a predetermined time interval; d. introducing a selected additive to the predetermined length of the web during the predetermined time period; and e. resuming the travel of the predetermined length of the web for a predetermined period and then stopping its travel again for additive introduction.
 2. The method of claim 1, wherein the continuously fed web is flattened and thereafter formed into a substantially U-shaped configuration prior to introduction of the additive.
 3. The method of claim 1, wherein the additive is introduced at spaced intervals in the direction of the axis of the web.
 4. The method of claim 1, wherein after the introduction of the additive the web is gathered into a rod of substantially cylindrical configuration.
 5. The method of claim 4, wherein a wrapper is fed intermittently in synchronization with the movement of the web axis as applied about the cylindrical rod.
 6. The method of claim 5, wherein the wrapped rod is transversely cut in synchronization with movement of the web and wrapper into lengths each having at least one intermediate zone with the selected additive.
 7. A method of manufacturing multiple tobacco smoke filters comprising the steps of: a. providing a web of filter material, said web having an elongated axis and being continuous in the direction of said axis; b. continuously feeding the web in the direction of said axis; c. flattening said web into a predetermined width; d. forming the flattened web into a substantially U-shaped configuration; e. stopping the travel of the U-shaped web for a predetermined time interval; f. providing a supply of particulate material; g. receiving a metered amount of the particulate material from its source of supply and at spaced intervals; h. delivering the spaced metered amounts of particulate material to the web immediately after it is formed in its U-shaped configuration; i. depositing the spaced metered amounts of the delivered particulate material into the interior of the web while stationary and at the base of the U and between the legs of the U whereby metered amounts of the particulate material will be located on the web at predetermined spaced intervals; j. resuming the travel of the U-shaped web having the spaced metered amounts of particulate material thereon; and k. immediately closing the legs of the web about the spaced metered amount of particulate material substantially immediately after the particulate material is deposited and forming it into a cylindrical rod.
 8. The invention in accordance with claim 7, wherein a wrapper is applied about the cylindrical rod.
 9. The invention in accordance with claim 8, wherein the wrapper rod is transversely cut into lengths each having at least one intermediate portion containing a pocket with the particulate material within the web of selective filter material.
 10. The invention in accordance with claim 9 wherein the feed of the tow with spaced particulate material is synchronized with the feed of the wrapper and the cutting of the rod.
 11. The invention in accordance with claim 7 wherein the supply of particulate material is a hopper, gravity feeding the particulate material from hopper, delivering metered amounts of the particulate material from the hopper to spaced dispensing apertures at a location above the web when the tow is stationary to enable the metered amounts of particulate material to be dispensed onto the stationary web at the predetermined spaced intervals.
 12. The invention in accordance with claim 11 wherein suction is applied to the stationary tow as the metered amounts of particulate material are dispensed thereon to expedite the dispensing operation and restrict movement of the particulate material on the web.
 13. Apparatus for manufacturing multiple tobacco smoke filters comprising: a. filter material supply means for supplying a web of filter material, said web having an elongated axis and being continuous in the direction of the axis; b. feed means for continuously feeding the web in the direction of the axis; c. dwell means for stopping the travel of a predetermined length of the web for a predetermined period of time; d. additive introduction means for introducing a selected additive over the predetermined length of web in the web during the predetermined period of time; and e. means for resuming the travel of the predetermined length of web after the additive was introduced to expose the next succeeding such length of web to the additive introduction means.
 14. The invention in accordance with claim 13, wherein a dancer roll means is interposed between the feed means and additive introduction means to accommodate the web being continuously fed during the dwell periods.
 15. The invention in accordance with claim 14, wherein a trumpet means is interposed between the dancer roll means and the additive introduction means to form the web into substantially U-shaped configuration.
 16. The invention in accordance with claim 13, wherein the additive introduction means includes a hopper means for supplying a particulate material to spaced dispensing apertures arranged along axis of web, a reciprocal dispensing plate with cavities for holding metered amounts of the particulate material, the plate reciprocating from a first position placing cavities under hopper means to receive the particulate material and a second position during the dwell period with the cavities over and aligned with the apertures whereupon the metered amounts of particulate material are deposited on the web at spaced intervals.
 17. The invention in accordance with claim 16, wherein suction means beneath the apertures and web expedite the deposit of particulate material from the aperture onto the web.
 18. The invention in accordance with claim 13, wherein garniture means immediately adjacent the additive introduction means gathers the web and forms it into a rod.
 19. The invention in accordance with claim 18, wherein a wrapper is fed intermittently and in synchronization with the web and the garniture means cooperates in enclosing the rod in a wrapper.
 20. The invention in accordance with claim 19, wherein a cutting means synchronized with the movement of the web the movement of the web and wrapper cuts the wrapped rod into lengths each having at least an intermediate zone of the additive. 